Method and system for interconnecting structural panels

ABSTRACT

A panel may be configured with panel mounts by forming a panel connector accepting slot in the panel and then locating connector mounts in the slot. In another embodiment, a panel may be configured with panel connector mounts by milling a panel to leave areas of panel material which form the mounts and milling the panel behind to connector mounts to define areas for accepting portions of the panel connector. Panels having the defined connector mounts may be connected by one or more panel connectors which engage the connector mounts.

RELATED APPLICATION DATA

The present application is a continuation of U.S. application Ser. No.15/807,675 filed Nov. 9, 2017, which claims priority to U.S. ProvisionalApplication Ser. No. 62/421,767, filed Nov. 14, 2016. The contents ofsaid prior applications are incorporated by reference as if set forthherein.

FIELD OF THE INVETION

Aspects of the invention comprise methods and systems for connectingpanel members, as well as methods for forming or configuring panelmembers with connector mounts.

SUMMARY OF THE INVENTION

Aspects of the invention comprise methods of forming or locating mountsin panels, such as structural panels. In one embodiment, the mountscomprise brackets which are connected to the panels, and in otherembodiments, portions of the panels comprise the mounts. Other aspectsof the invention comprise panels having panel connector mounts andmethods of connecting two or more panels, such as via one or more panelconnectors.

In one embodiment, a panel may be configured with panel or connectormounts by forming a panel connector accepting slot in the panel and thenlocating one or more connector mounts in the slot. In one embodiment,the connector mount comprises a bracket and a bore may be formed whichprovides an access way for positioning the bracket in the slot.

In one embodiment, the bracket is mounted in a mounting channel which isformed in the slot. The mounting channel intersects the bore. The slotmay have a first depth and the mounting channel may be located at asecond, lesser depth. In this manner, a space is defined behind thebracket within the slot for accepting a portion of a panel connector.

In one embodiment, the bracket has at least one portion having a widthwhich is greater than a width of the slot. The bracket may comprise, forexample, a pair of washers which are connected to a mount, the mounthaving a width less than a width of the slot and the washers having adiameter which is greater than a width of the slot but smaller than thebore.

In another embodiment, a panel may be configured with panel connectormounts by milling a panel to leave areas of panel material which formthe mounts and milling the panel to leave recesses for acceptingportions of the panel connector. In one embodiment, slots are milled ina face or edge of a panel to define the connector mounts and one or morerecesses are milled into the panel perpendicular to the slots to definean open area behind each panel connector into which a portion of a panelconnect may be positioned. In another embodiment, slots are formed in aface or edge of a panel to define the connector mounts, a bore is formedin alignment with each slot and then a cutter is lowered into each boreand moved along each slot to remove material from behind each slot toform a recess behind the connector mount.

In one embodiment, panels having the mounts are connected via one ormore panel connectors. The panel connectors may have at least oneprojection extending outwardly from first and second edges of the panel.The projections extending from one edge are engaged with the mounts ofone panel and the projections extending from the opposing edge areengaged with the mounts of another panel, securing the panels to oneanother.

Further objects, features, and advantages of the present invention overthe prior art will become apparent from the detailed description of thedrawings which follows, when considered with the attached figures.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a portion of a panel having a connectormount associated therewith in accordance with one embodiment of theinvention;

FIG. 2 is a plan view of an edge portion of the panel illustrated inFIG. 1;

FIG. 3 is a perspective view of the connector mount illustrated in FIG.1;

FIG. 4 is a cross-sectional side view of a portion of the panelillustrated in FIG. 1 with a panel connector engaged therewith;

FIG. 5 is a perspective view of portion of a panel having connectormounts formed in accordance with another embodiment of the invention;and

FIG. 6 is a perspective view of a portion of a panel having connectormounts formed in accordance with yet another embodiment of theinvention.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, numerous specific details are set forth inorder to provide a more thorough description of the present invention.It will be apparent, however, to one skilled in the art, that thepresent invention may be practiced without these specific details. Inother instances, well-known features have not been described in detailso as not to obscure the invention.

The present invention comprises methods and systems for connecting panelmembers, including methods of making or forming panel connectionelements.

The present invention is applicable to panel members of a variety ofconfigurations and which may be used for various purposes. Examples ofpanel members are disclosed in U.S. Pat. No. 9,068,581, which isincorporated herein in its entirety by reference. The panels or panelmembers are preferably generally planar, having front and back faces, atop edge, a bottom edge, a pair of side edges and generally have athickness dimension (from front to back) which is less (and usually muchless) than the height and/or length of the panel. The panels may haveany size and may have varying shapes. The panel might, for example, besquare or rectangular in shape. In one embodiment, at least one sideedge of a panel is straight, and preferably vertically oriented tofacilitate the connection of the panel to another panel as describedherein.

A panel of the invention might be used for or comprise a dividerelement, a wall element, a portion of a piece of furniture, or be usedin various other manners. The panels might be solid, hollow core or havevarious other configurations, and may be constructed of a variety ofmaterials such as wood or even plastic or the like.

U.S. Pat. No. 9,068,581 describes, among other things, a configurationin which anchor members may be located at edge portions of panels, theanchor members defining one or more connector mounts for connection toone or more panel connectors (see e.g. FIG. 4, wherein an anchor 100 islocated in a slot at the edge of a panel, the anchor 100 defining aplurality of mounting 120, and wherein a panel connector 150 isconfigured to engage the panel, including the mounts 120, for connectingthe panel to one or more other panels).

However, in some cases, forming a slot in a panel for acceptance of suchan anchor can be problematic. For example, in some cases the formationof a slot from top to bottom along an edge of the panel allows layers ofthe panel to begin to peel or separate, or otherwise reduces thestructure integrity and longevity of the panel.

FIG. 1 illustrates a panel P having a front face FF, a top edge TE, anda side edge SE. A slot S is formed in the side edge SE of the panel P.The slot S need not extend from the top edge TE to the bottom edge BE ofthe panel P, but might extend only along a portion of the side edge SE.Further, the slot S could be a single slot or a series of slots. Thewidth and depth of the slot S are preferably selected to allow the slotS to accept therein at least a connection portion of a panel connector,such as the panel connector 350 illustrated in FIG. 4. As noted in U.S.Pat. No. 9,068,581, such panel connectors may have a variety ofconfigurations. In one embodiment, the slot S has a depth which is atleast equal to half of the width of a panel connector to be usedtherewith (whereby when two panels are connected, the edges thereof maycontact with the panel connector which is connecting the two panelsbeing located completely in the slots of the two panels). While the slotS may be relatively elongate compared to its width, the slot could haveother shapes, such as depending upon the style of the panel connector.For example, the slot S could comprise one or more apertures, openings,insets or the like.

Importantly, one or more connector mounts 320 are associated with thepanel P. Preferably, the mounts 320 are located in the slot(s) S.

The connector mounts 320 may have various configurations. In oneembodiment, as illustrated in FIG. 3, the connector mount 320 comprisesa pair of washers 351 which are connected to a bracket 352 by fasteners353. The bracket 352 may comprise, for example, a rectangular metal bodywhich has a width close to (but less than) the width of the slot S. Thewashers 351 have a diameter which exceeds the width of the slot S butwhich is less than the diameter of the bore B. In this manner, thebracket 352 may simply be positioned in the slot S by passing thewashers 351 through the bore B.

One embodiment of the invention is an innovative method for placing aconnector mount 320. As illustrated in FIG. 1, a bore B is formed in theside edge SE of the panel P. The center of the bore B is co-extensive(e.g. the centerline of the bore B extends through the slot S) with theslot S. The diameter of the bore B is preferably slightly greater thanthe diameter of the washers 351. A mounting channel or secondary slot MSis formed in portions of the panel which define the slot S, extendinglaterally from the bore B. This mounting channel MS is inset into theslot S from the side edge SE of the panel, but it located above thebottom of the slot S. The bore B may, for example, be formed with adrill, router, CNC machine or the like, as may be the mounting channelMS. It will be appreciated that while the bore B might be cylindrical inshape, it might have other shapes, such as being elongated.

The user places the washers 351 down the bore B until they reach themounting channel MS. The user then slides one washer 351 into themounting channel MS below the bore B and one above the bore B. The userthen positions the bracket 352 in the slot S and connects it to thewashers 351 using the fasteners 353. At that time, the mount 320 cannotmove forward or back in the slot S because the washers 351 are fixed inthe mounting channel MS. At the same time, the mount 320 cannot move upor down for the same reason. The connector mount 320 thus defines asecure mounting point for a portion of a panel connector, such as thepanel connector 350 which is illustrated in FIG. 4.

Such a panel connector 350 may have various configurations, such asillustrated in U.S. Pat. No. 9,068,581. In one embodiment, the panelconnector 350 is generally planar, having a front face 356 and anopposing rear face (not visible in FIG. 4). The panel connector 350 mayhave a first side edge 358 and an opposing second side edge 360. One ormore projections 354 extend outwardly from the panel connector 350,preferably from each side edge 358,360. It will be appreciated that thenumber of projections, their shape and spacing, may vary. In general,each projection 354 preferably defines a mount-accepting slot or area362 between it and the main body of the panel connector 350.

As illustrated in FIG. 4, a panel P fitted with the mounts 320 may beconnected to another panel or panels, or other supports, using the panelconnector 350. In particular, the panel connector 350 can be extendedinto the slot S and the panel connector 350 and panel P may be movedrelative to one another so that the projection(s) 354 extend over acorresponding mount 320. At this time, the mount 320 is located in theslot 362 defined between the main body of the panel and the projection354, with a portion of the projection 354 extending behind the mount 320in the slot S. In this configuration, the panel connector 350 isprevented from moving in and out of the panel P as described in U.S.Pat. No. 9,068,581 (e.g. the panel connector 350 cannot be movedlaterally, but is secured to the panel P). Of course, the opposing edge360 of the panel connector 350 may be connected to another panel P,thereby connecting the two panel in a side edge to side edgeconfiguration (e.g. one where the panels P are connected so that theyare positioned in the same plane and cannot separate from one anotherlaterally).

As noted in U.S. Pat. No. 9,068,581, such panel connectors may have avariety of configurations, including configurations which allow panelsto be mounted at angles relative to one another, in configurations wheremore than two panels are connected to one another, and the like. Ofcourse, other types of panel connectors might be utilized and more thanone panel connector might be utilized to connect one or more panels.Also, a panel P having mounts might be connected to structures otherthan other panels, such as walls and the like.

Of course, a panel P might be fitted with a plurality of mounts 320. Forexample, if a panel connector 350 has four spaced-apart projections 354,the panel P is preferably fitted with four corresponding mounts 320 atcorresponding positions. Further, a panel P could be fitted with variousconfigurations of mounts 320, such as to permit two or more differentpanel connectors 350 to be used therewith (such as where the panelconnectors 350 have projections 354 in different locations or the like).

Of course, the mount 320 might have other configurations than justdescribed and may be associated with the slot in other manners. Forexample, in one embodiment, the mounts 320 comprise at least a firstelement (and preferably first and second elements) which are mounted toa third element. At least one of the elements preferably has a width orother dimension which is greater than the width of the slot S, and mostpreferably, less than that of the bore B, thus allowing it to bepositioned in the slot S via the bore B but preventing it from passingthrough the slot alone. In other embodiments, it is possible for themount 320 to comprise a single element or just two elements. Forexample, in one embodiment the mount 320 might comprise an element whichhas at least one dimension which is wider or greater than that of theslot S, but smaller than the bore B, thus allowing the element to belowered into the slot only through the bore and to then be positionedtherein, such as in an associated mounting channel. The element might belocated in a lower portion of the mounting channel (below the bore),whereby downward force by a panel connector thereon aids in retainingthe element in position.

Preferably, the mount 320 can easily be associated with the panel Pafter formation of the slot S, once fitted is securely affixed to thepanel P (e.g. will not fall out, etc., such as if the panel P ispositioned in different orientations, can't be pulled out of the slot,etc.), and can be associated with the panel P with minor associatedmodification of the panel P (such as by boring a simple bore B). Also,the mount 320 does not extend outwardly from the side edge SE of thepanel P and thus does not prevent panels from being placed directlyadjacent to one another in a side to side position.

As another example, in one embodiment, a connector mount 320 mightcomprise a member which will fit into the bore B and which can then beextended (such as by expanding it) so that its length increases, thuscausing the ends thereof to anchor into the mounting channel MS of thepanel P. In another embodiment, the connector mount 320 might comprise awedge type element which can be located in the slot S and then slidapart to increase its width, thus again causing it to be mounted to thepanel.

In many applications, the integrity of the front and back of the panelis important, such as for aesthetic purposes. The above-described methodpermits a connector mount to be associated with a panel by onlyaccessing the edge of the panel, rather than the front or back, thusavoiding having to resurface the front or back of the panel in suchsituations.

In other situations, it may be permissible to alter the front and/orback of the panel, such as where aesthetics are not as important, butwhere the strength of the panel is still critical. Another embodiment ofthe invention will be described with reference to FIG. 5. FIG. 5 alsoillustrates a panel P, such as similar to that described above. In thisembodiment, a plurality of slots S (S1, S2, etc.) are formed in the sideedge SE of the panel P. The slots S might be formed in various manners,such as by milling (e.g.—removing panel material), such as via a toolsuch as a router, CNC machine, etc. Preferably, the slots S are spacedapart from one another, thus leaving or defining a connector mount 420therebetween (in one embodiment, a portion of the side edge SE of thepanel may be removed at the location of the connector mount 420 so thatthe front of the connector mount is inset from the side edge SE of thepanel P).

Of course, a number of slots S may be formed along the side edge SE ofthe panel P, thus defining a plurality of connector mounts 420 (whichcomprise portions of panel material between two adjacent slots). Again,the number of defined connector mounts 420 and their location may bechosen to mate with one or more panel connector projections of variousconfigurations (such as to mate with a panel connector having a certainconfiguration of projections).

In order to permit the projection of a panel connector (such as theprojection 354 illustrated in FIG. 4) to be extended into one of theslots S and then moved downwardly over the connector mount 420 so thatthe connector mount 420 is located in the slot between the projectionand the main body of the panel connector, a space must be defined behindthe connector mount 420 for accepting the connector projection. Thus, arecess R is formed behind the connector mount 420. In a preferredembodiment, this recess R is formed by milling (e.g.—removing panelmaterial), such as via a tool such as a router, CNC machine, etc. Asillustrated, the recess R may be formed in the front face FF of thepanel P, near the side edge SE. In particular, the router or tool may beused to remove material laterally into the panel from the front face FFuntil a void or recess is formed behind the connector mount 420. In thisconfiguration, the recess R extends perpendicular to the slots S.

Of course, more than one recess R can be formed, such as onecorresponding to each connector mount 420, or large recesses may beformed corresponding to multiple connector mounts. In the embodimentillustrated in FIG. 5, a recess R is formed corresponding to eachconnector mount 420. In this configuration, only small spaced apartrecesses are formed along the length of the panel P, rather than anelongate recess. Because panel material remains between each recess R,the panel P is much stronger. In this configuration, each individualrecess R might be formed, for example, by extending a circular cuttingblade into the panel P to remove material from behind the connectormount 420.

Of course, the recess or recesses behind the connector mounts 420 mightbe formed in other manners. For example, referring to FIG. 6, slots S(S1, S2, etc.) might be formed in the side edge SE of a panel P. A boreB might then be formed which intersects or overlaps each slot S, such asin the middle of each slot. The bore B preferably has a depth which isgreater than the slot S. A rotary cutter, such as a wing cutter, maythen be extended into the bore B and may be moved along the length ofeach slot S thus removing panel material from behind the slot S, atleast in the area between the slots, thus defining a panel connector 420with a recessed space there behind for accepting a portion of a panelconnector.

In use, a user can extend the projections of a panel connector (notshown) into the slots S in the panel. The projections pass through theslots and into the recess(es). The user can then move the panelconnector and panel relative to one another so that the projections ofthe panel connector extend over the connector mounts 420 (e.g. theprojections thus extend behind the connector mounts into the recess(es)R behind the mounts), thereby locking the panel connector to the panelP. Of course, another panel may be connected to an opposing side of thesame panel connector, thus connecting two panels to one another.

It will be appreciated that the connector mounts 420 and associatedpanel connector accepting spaces associated therewith may be formed invarious manners. For example, while the slots S are shown as beingelongated in FIGS. 5 and 6, the slots might actually have other shapes,such as round or the like. Most preferably, the connector mounts 420simply comprise portions of the panel P which remain between two areaswhere panel material is removed and which are sized to accept a portionof a panel connector. Thus, for example, two holes might be drilled inthe panel P and the remaining panel material between the holes may formthe connector mount. In one embodiment, as illustrated, the slots S maybe themselves located in a slot or channel, such as illustrated in FIG.5. In this manner, a portion of a panel connected can be located in thechannel, with the projection(s) extending through the slots. The channelmay have a sufficient depth so that when a panel connector is locatedbetween two connected panels, the panel connector is located inside ofthe panels, thus allowing the side edges of the panels to be positioneddirectly against one another.

Of course, the location of the slots or other voids/apertures, as wellas the location of the recess(es) are chosen to facilitate panelconnector connection in a desired configuration. In the exampleillustrated in FIGS. 5 and 6, the connector mounts 420 are defined atthe side edge SE of the panel, whereby the panel is mounted to anotherpanel or structure at its side edge. However, the connector mounts 420might, for example, be defined in the front face FF or rear face of thepanel (whereby the recess R is defined in the side edge SE), at a top orbottom edge or the like. For example, if a user desired to connect afirst panel to a second panel at the middle of the second panel, theconnector mounts 420 would be formed in the middle of the front face FFof the second panel.

It will be understood that the above described arrangements of apparatusand the method there from are merely illustrative of applications of theprinciples of this invention and many other embodiments andmodifications may be made without departing from the spirit and scope ofthe invention as defined in the claims.

What is claimed is:
 1. A method of forming a panel with a panelconnector mount, said panel having a face in a first plane and an edgedefined by a solid panel material, said edge in a second plane which isoffset from said first plane, comprising the steps of: removing materialfrom said solid panel material to form forming a first slot and a secondslot in into said edge, said first slot positioned above said secondslot and said first and second slots spaced from one another to define aconnector mount therebetween; and removing material from said solidpanel material forming a recess in said panel behind said connectormount to form a recess behind said connector mount, wherein said recessextends inwardly from said face, and wherein said recess intersects atleast a portion of said first slot.
 2. The method in accordance withclaim 1 wherein said first plane and said second plane are generallyperpendicular to one another.
 3. The method in accordance with claim 1wherein said panel further has a second opposing face and wherein saidedge is located between said first and second faces.
 4. The method inaccordance with claim 1 comprising using a router to remove saidmaterial to form said first and second slots and said recess.
 5. Themethod in accordance with claim 1 wherein said first and second slotsare elongate and each have a length greater than a length of saiddefined connector mount between said first and second slots.
 6. Themethod in accordance with claim 1 wherein said recess extends behindsaid connector mount and intersects at least a portion of both of saidfirst and second slots.
 7. A method of connecting a first generallyplanar panel having a first face in a first plane and a first edgedefined by a solid panel material, said first edge in a second planewhich is offset from said first plane and a second generally planarpanel having a second face in a third plane and a second edge defined bya solid panel material, said second edge in a fourth plane which isoffset from the third plane, comprising the steps of: removing materialfrom said solid panel material to form forming a first slot and a secondslot into said first edge of said first generally planar panel, saidfirst slot positioned above said second slot and said first and secondslots spaced from one another to define a connector mount therebetween;removing material from said solid panel material of said forming arecess into said first generally planar panel to form a recess behindsaid connector mount, wherein said recess extends inwardly from saidfirst face and behind said connector mount and connects to at least aportion of said first slot; removing material from said solid panelmaterial to form forming a first slot and a second slot into said secondedge of said second generally planar panel, said first slot positionedabove said second slot and said first and second slots spaced from oneanother to define a connector mount therebetween; removing material fromsaid solid panel material of said forming a recess into said secondgenerally planar panel to form a recess behind said connector mount,wherein said recess extends inwardly from said second face and behindsaid connector mount and connects to at least a portion of said firstslot; extending a first projection extending from a first edge of panelconnector into said first slot in said first generally planar panel;positioning at least a portion of said first projection behind saidconnector mount in said recess in said first generally planar panel;extending a second projection extending from a second edge of said panelconnector into said first slot in said second generally planar panel;and positioning at least a portion of said second projection behind saidconnector mount in said recess in said second generally planar panel. 8.The method in accordance with claim 7 wherein said recess extends behindsaid connector mount and intersects at least a portion of both of saidfirst and second slots in said first generally planar panel.
 9. Themethod in accordance with claim 7 wherein said first plane and saidthird plane are parallel to one another and said second plane and saidfourth plane are parallel to one another when said first and secondgenerally planar panels are connected.